Wavelength conversion member and production method therefor

ABSTRACT

Provided is a wavelength conversion member that can be readily adjusted in chromaticity and can be increased in productivity and a production method for the wavelength conversion member. A wavelength conversion member 1 having a first principal surface 1a and a second principal surface 1b opposed to each other includes a glass matrix 2 and phosphor particles 3 disposed in the glass matrix 2, wherein concentrations of the phosphor particles 3 in the first principal surface 1a and in the second principal surface 1b are higher than concentrations of the phosphor particles 3 in surface layer bottom planes 1c and 1d located 20 μm inward from the first principal surface 1a and 20 μm inward from the second principal surface 1b, respectively.

TECHNICAL FIELD

The present invention relates to wavelength conversion members for converting the wavelength of light emitted from a light emitting diode (LED), a laser diode (LD) or the like to another wavelength and production methods therefor.

BACKGROUND ART

Recently, attention has been increasingly focused on light emitting devices and the like using LEDs or LDs, as next-generation light sources to replace fluorescence lamps and incandescent lamps. As an example of such a next-generation light source, there is a disclosure of a light emitting device in which an LED for emitting a blue light is combined with a wavelength conversion member capable of absorbing part of the light from the LED to convert it to a yellow light. This light emitting device emits a white light which is a synthesized light of the blue light emitted from the LED and the yellow light emitted from the wavelength conversion member. Patent Literature 1 proposes, as an example of a wavelength conversion member, a wavelength conversion member in which phosphor powder is dispersed in a glass matrix.

CITATION LIST Patent Literature

-   [PTL 1] -   JP-A-2003-258308

SUMMARY OF INVENTION Technical Problem

Such a wavelength conversion member as described in Patent Literature 1 is made by polishing a glass-based material including phosphor powder dispersed in a glass matrix to reduce its thickness. However, the amount of glass-based material ground away for obtaining a wavelength conversion member having a desired chromaticity may become large, so that productivity cannot sufficiently be increased.

An object of the present invention is to provide a wavelength conversion member that can be readily adjusted in chromaticity and can be increased in productivity and a production method for the wavelength conversion member.

Solution to Problem

A wavelength conversion member according to the present invention is a wavelength conversion member having a first principal surface and a second principal surface opposed to each other and includes a glass matrix and phosphor particles disposed in the glass matrix, wherein concentrations of the phosphor particles in the first principal surface and in the second principal surface are higher than concentrations of the phosphor particles in portions 20 μm inward from the first principal surface and 20 μm inward from the second principal surface.

It is preferred that a concentration of the phosphor particles in a middle portion between the first principal surface and the second principal surface be low and a concentration of the phosphor particles increase toward the first principal surface and toward the second principal surface.

A method for producing a wavelength conversion member according to the present invention is a method for producing the wavelength conversion member constructed according to the present invention and includes the steps of: preparing a slurry containing glass particles to be the glass matrix and the phosphor particles; applying the slurry to substrates, drying the slurry, and allowing the phosphor particles to sediment downward before completion of the drying to obtain first and second green sheets in each of which a concentration of the phosphor particles in an under surface is higher than a concentration of the phosphor particles in a top surface; and stacking the first and second green sheets so as to superpose the top surfaces thereof and bonding and firing the first and second green sheets together.

The method preferably further includes the step of polishing the first principal surface and/or the second principal surface of the wavelength conversion member.

Advantageous Effects of Invention

The present invention enables provision of a wavelength conversion member capable of being readily adjusted in chromaticity and capable of being increased in productivity and a production method for the wavelength conversion member.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic cross-sectional front view of a wavelength conversion member according to a first embodiment of the present invention.

FIG. 2 is a schematic plan view showing the concentration of phosphor particles in a first principal surface of the wavelength conversion member according to the first embodiment of the present invention.

FIG. 3 is a schematic cross-sectional plan view showing the concentration of phosphor particles in a surface layer bottom plane 20 μm inward from the first principal surface of the wavelength conversion member according to the first embodiment of the present invention.

FIGS. 4(a) to 4(d) are schematic cross-sectional front views for illustrating an example of a method for producing the wavelength conversion member according to the first embodiment of the present invention.

FIG. 5 is a schematic cross-sectional front view of a wavelength conversion member according to a second embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

Hereinafter, a description will be given of preferred embodiments. However, the following embodiments are merely illustrative and the present invention is not limited to the following embodiments. Throughout the drawings, members having substantially the same functions may be referred to by the same reference characters.

First Embodiment

FIG. 1 is a schematic cross-sectional front view of a wavelength conversion member according to a first embodiment of the present invention. As shown in FIG. 1, a wavelength conversion member 1 includes a glass matrix 2 and phosphor particles 3 disposed in the glass matrix 2. The wavelength conversion member 1 has first and second principal surfaces 1 a, 1 b opposed to each other.

In this embodiment, the first principal surface 1 a is an incident surface allowing excitation light to be incident thereon. The phosphor particles 3 emit fluorescence upon entry of excitation light into the wavelength conversion member 1. The second principal surface 1 b is an exit surface allowing the fluorescence and the excitation light to exit the wavelength conversion member 1 therethrough. Note that in this embodiment the direction in which the first principal surface 1 a and the second principal surface 1 b are opposed to each other is a thickness direction.

No particular limitation is placed on the type of the glass matrix 2 so long as it can be used as a dispersion medium for the phosphor particles 3, such as inorganic phosphor. For example, borosilicate glass, phosphate glass, tin-phosphate glass or bismuthate glass can be used. Examples of the borosilicate glass include those containing, in % by mass, 30 to 85% SiO₂, 0 to 30% Al₂O₃, 0 to 50% B₂O₃, 0 to 10% Li₂O+Na₂O+K₂O, and 0 to 50% MgO+CaO+SrO+BaO. Examples of the tin-phosphate glass include those containing, in % by mole, 30 to 90% SnO and 1 to 70% P₂O₅. The softening point of the glass matrix 2 is preferably 250° C. to 1000° C., more preferably 300° C. to 950° C., and still more preferably in a range of 500° C. to 900° C. If the softening point of the glass matrix 2 is too low, the mechanical strength and chemical durability of the wavelength conversion member 1 may decrease. Furthermore, because the thermal resistance of the glass matrix 2 itself decreases, the wavelength conversion member 1 may be softened and deformed by heat generated by the phosphor particles 3. On the other hand, if the softening point of the glass matrix 2 is too high, the phosphor particles 3 may be deteriorated by a firing process during production, so that the luminescence intensity of the wavelength conversion member 1 may decrease. The glass matrix 2 is preferably alkali-free glass. Thus, deactivation of the phosphor particles 3 can be prevented. From the viewpoint of increasing the mechanical strength and chemical durability of the wavelength conversion member 1, the softening point of the glass matrix 2 is preferably not less than 500° C., more preferably not less than 600° C., still more preferably not less than 700° C., yet still more preferably not less than 800° C., and particularly preferably not less than 850° C. An example of such a glass is borosilicate glass. However, if the softening point of the glass matrix 2 rises, the firing temperature also rises and, as a result, the production cost tends to rise. Therefore, from the viewpoint of inexpensively producing the wavelength conversion member 1, the softening point of the glass matrix 2 is preferably not more than 550° C., more preferably not more than 530° C., still more preferably not more than 500° C., yet still more preferably not more than 480° C., and particularly preferably not more than 460° C. Examples of such a glass include tin-phosphate glass and bismuthate glass.

No particular limitation is placed on the type of the phosphor particles 3 so long as they emit fluorescence upon entry of excitation light. A specific example of the type of the phosphor particles 3 is one or more selected from the group consisting of oxide phosphor, nitride phosphor, oxynitride phosphor, chloride phosphor, oxychloride phosphor, sulfide phosphor, oxysulfide phosphor, halide phosphor, chalcogenide phosphor, aluminate phosphor, halophosphoric acid chloride phosphor, and garnet-based compound phosphor. When using a blue light as the excitation light, for example, a phosphor emitting a green light, a yellow light or a red light as fluorescence can be used.

The average particle diameter of the phosphor particles 3 is preferably 1 μm to 50 μm and more preferably 5 μm to 25 μm. If the average particle diameter of the phosphor particles 3 is too small, the luminescence intensity may decrease. On the other hand, if the average particle diameter of the phosphor particles 3 is too large, the luminescent color may be uneven.

The content of the phosphor particles 3 in the glass matrix 2 is preferably in a range of 1 to 70% by volume, more preferably in a range of 1.5 to 50% by volume, and still more preferably in a range of 2 to 30% by volume. If the content of the phosphor particles 3 is too small, the luminescence intensity of the wavelength conversion member 1 may be insufficient. On the other hand, if the content of the phosphor particles 3 is too large, a desired luminescent color may not be able to be obtained. In addition, the mechanical strength of the wavelength conversion member 1 may decrease.

The thickness of the wavelength conversion member 1 is preferably in a range of 0.01 mm to 1 mm, more preferably in a range of 0.03 mm to 0.5 mm, still more preferably in a range of 0.05 mm to 0.35 mm, particularly preferably in a range of 0.075 mm to 0.3 mm, and most preferably in a range of 0.1 mm to 0.25 mm. If the thickness of the wavelength conversion member 1 is too large, scattering and absorption of light in the wavelength conversion member 1 may become too much, so that the efficiency of emission of fluorescence may become low. If the thickness of the wavelength conversion member 1 is too small, sufficient luminescence intensity may be less likely to be obtained. In addition, the mechanical strength of the wavelength conversion member 1 may be insufficient.

A feature of this embodiment is that the concentrations of phosphor particles 3 in the first principal surface 1 a and in the second principal surface 1 b are higher than the concentrations of phosphor particles 3 in portions 20 μm inward from the first principal surface 1 a and 20 μm inward from the second principal surface 1 b. A description will be given of the feature of this embodiment with reference to FIGS. 1 to 3.

As shown in FIG. 1, in this embodiment, a plane of the wavelength conversion member 1 located 20 μm inward from the first principal surface 1 a is referred to as a surface layer bottom plane 1 c. Likewise, a plane of the wavelength conversion member 1 located 20 μm inward from the second principal surface 1 b is referred to as a surface layer bottom plane 1 d. A region from the first principal surface 1 a to the surface layer bottom plane 1 c and a region from the second principal surface 1 b to the surface layer bottom plane 1 d are surface layers B in this embodiment. Furthermore, a region between the surface layer bottom plane 1 c and the surface layer bottom plane 1 d is a middle portion A in this embodiment.

FIG. 2 is a schematic plan view showing the concentration of phosphor particles 3 in the first principal surface 1 a. FIG. 3 is a schematic cross-sectional plan view showing the concentration of phosphor particles 3 in the surface layer bottom plane 1 c located 20 μm inward from the first principal surface 1 a. As shown in FIGS. 2 and 3, the area occupancy of phosphor particles 3 in the first principal surface 1 a is larger than that of phosphor particles 3 in the surface layer bottom plane 1 c. Therefore, the concentration of phosphor particles 3 in the first principal surface 1 a is higher than that of phosphor particles 3 in the surface layer bottom plane 1 c located 20 μm inward from the first principal surface 1 a.

Likewise, on the second principal surface 1 b side, the area occupancy of phosphor particles 3 in the second principal surface 1 b is larger than that of phosphor particles 3 in the surface layer bottom plane 1 d. Therefore, the concentration of phosphor particles 3 in the second principal surface 1 b is higher than that of phosphor particles 3 in the surface layer bottom plane 1 d located 20 μm inward from the second principal surface 1 b.

The area occupancy of phosphor particles 3 in each of the first principal surface 1 a and the second principal surface 1 b is preferably not less than 140% of the area occupancy of phosphor particles 3 in each of the surface layer bottom plane 1 c and the surface layer bottom plane 1 d, more preferably not less than 160% thereof, still more preferably not less than 200% thereof, preferably not more than 1000% thereof, more preferably not more than 500% thereof, and still more preferably not more than 330% thereof. If the area occupancy is too small, the amount of change in chromaticity upon polishing is too small, so that the production efficiency tends to decrease. On the other hand, if the area occupancy is too large, the amount of change in chromaticity upon polishing is too large, which makes it difficult to adjust the chromaticity with high accuracy.

The area occupancy is calculated by digitizing each of SEM (scanning electron microscopic) images of the principal surfaces and surface layer bottom planes and determining the proportion of the area of portions occupied by phosphor particles per unit area of the image. As for the surface layer bottom planes, their images are taken with the surface layer bottom planes exposed by polishing the principal surfaces.

In this embodiment, the concentration of phosphor particles 3 in the middle portion A between the first principal surface 1 a and the second principal surface 1 b is low and the concentration of phosphor particles 3 increases toward the first principal surface 1 a and toward the second principal surface 1 b. More specifically, the wavelength conversion member 1 according to this embodiment has a concentration gradient in which the concentration of phosphor particles 3 gradually increases from the center of the middle portion A toward the first principal surface 1 a and toward the second principal surface 1 b. Therefore, the surface layers B also have a concentration gradient in which the concentration of phosphor particles 3 gradually increases toward the first principal surface 1 a and toward the second principal surface 1 b. Although in FIG. 1 the phosphor particles 3 are not shown in the middle portion A, the middle portion A may also contain the phosphor particles 3 as shown in FIG. 3. For the purpose of showing a high concentration of phosphor particles 3 in the surface layers B, FIG. 1 shows the phosphor particles 3 in the surface layers B only.

The wavelength conversion member 1 is used for the purpose of converting the wavelength of entered excitation light and emitting fluorescence. In the case of a white light emitting device, a white light, for example, which is a synthesized light of a blue light as excitation light from a light source, such as an LED, and a yellow light as fluorescence, is emitted from the wavelength conversion member 1. The adjustment of the chromaticity of light to be emitted from the wavelength conversion member 1 is generally achieved by polishing at least one of the first principal surface 1 a and the second principal surface 1 b of the wavelength conversion member 1 to reduce the thickness of the wavelength conversion member 1. By reducing the thickness of the wavelength conversion member 1, the proportion of fluorescence emitted from the wavelength conversion member 1 can be reduced and the proportion of excitation light passing through the wavelength conversion member 1 can be increased. The adjustment of the thickness of the wavelength conversion member 1 is generally achieved by polishing within the regions of the surface layers B.

In this embodiment, the concentrations of phosphor particles 3 in the first principal surface 1 a and in the second principal surface 1 b are higher than the concentrations of phosphor particles 3 in the surface layer bottom plane 1 c and in the surface layer bottom plane 1 d. Therefore, the change in chromaticity relative to the change in thickness due to polishing of the first principal surface 1 a or the second principal surface 1 b is large. In other words, the chromaticity can be largely changed even if the amount of material ground away by polishing is small and, therefore, the chromaticity can be readily adjusted. Hence, according to this embodiment, the chromaticity can be readily adjusted, so that the productivity can be increased.

Hereinafter, a description will be given of an example of a method for producing the wavelength conversion member 1.

(Method for Producing Wavelength Conversion Member)

FIGS. 4(a) to 4(d) are schematic cross-sectional front views for illustrating an example of a method for producing the wavelength conversion member according to the first embodiment.

In the method for producing the wavelength conversion member 1, first, a slurry is prepared which contains glass particles to be a glass matrix, phosphor particles, and organic components including a binder resin and a solvent. Next, as shown in FIG. 4(a), the slurry 4 is applied onto a resin film 6 made of polyethylene terephthalate or other resins and serving as a substrate, by the doctor blade method or other methods.

Next, the slurry 4 is dried. In doing so, the phosphor particles 3 are allowed to sediment downward before the completion of the drying of the slurry 4. Thus, as shown in FIG. 4(b), a first green sheet 5A is obtained in which the concentration of phosphor particles 3 in the under surface 5Ab is higher than the concentration of phosphor particles 3 in the top surface 5Aa.

Note that the density of glass particles in the slurry 4 is smaller than the density of phosphor particles 3 therein. Therefore, the phosphor particles 3 can be suitably allowed to sediment. Thus, in the first green sheet 5A, the above-mentioned concentration distribution of the phosphor particles 3 can be more securely achieved.

On the other hand, a second green sheet 5B shown in FIG. 4(c) is obtained in the same manner as the process shown in FIGS. 4(a) and 4(b). Also in the second green sheet 5B, the concentration of phosphor particles 3 in the under surface 5Bb is higher than the concentration of phosphor particles 3 in the top surface 5Ba.

Next, as shown in FIG. 4(c), the first and second green sheets 5A, 5B are stacked so as to superpose their top surfaces 5Aa, 5Ba. Next, the first and second green sheets 5A, 5B are bonded together by the application of heat and pressure and fired. Thus, a wavelength conversion member 1A shown in FIG. 4(d) is produced.

In addition, both or one of the first principal surface 1 a and the second principal surface 1 b of the wavelength conversion member 1A may be polished to adjust the chromaticity of the wavelength conversion member 1A. In the first embodiment, the first and second principal surfaces 1 a, 1 b are polished, thus obtaining the wavelength conversion member 1 shown in FIG. 1. No particular limitation is placed on the polishing method and it can be provided, for example, by lapping or mirror polishing. Lapping has the advantage of having a higher polishing speed than mirror polishing. On the other hand, mirror polishing can increase the accuracy of a polished surface as compared to lapping. The thickness and chromaticity of the wavelength conversion member 1A have a correlation. Therefore, if this correlation is previously determined, a target thickness of the wavelength conversion member 1A for obtaining a desired chromaticity can be determined. The correlation between the thickness and the chromaticity can be determined, for example, by measuring the thickness and chromaticity while keeping on polishing in conditions of higher chromaticity than a target chromaticity. In this case, from the viewpoint of determining the correlation between chromaticity and thickness with high accuracy, it is preferred to adopt a polishing method providing a surface condition (surface roughness) equivalent to that of the finished surface of a final product. For example, if the product is finished by mirror polishing, mirror polishing is preferably also adopted in the polishing method for determining the correlation between chromaticity and thickness.

Second Embodiment

FIG. 5 is a schematic cross-sectional front view of a wavelength conversion member according to a second embodiment. A wavelength conversion member 11 according to this embodiment can be produced by stacking not only the first and second green sheets 5A, 5B shown in FIG. 4(c) but also a third green sheet made in the same manner as for the first and second green sheets 5A, 5B. Specifically, the wavelength conversion member 11 can be produced by laying the top surface of the third green sheet, the top surface having a lower concentration of phosphor particles 3, on the laminate of the first and second green sheets 5A, 5B and bonding and firing them together.

Also in this embodiment, the concentrations of phosphor particles 3 in a first principal surface 11 a and in a second principal surface 11 b are higher than the concentrations of phosphor particles 3 in a surface layer bottom plane 11 c and in a surface layer bottom plane 11 d. Therefore, even if the amount of material ground away by polishing the first principal surface 11 a or the second principal surface 11 b is small, the chromaticity can be largely changed. Hence, the chromaticity can be readily adjusted, so that the productivity can be increased.

REFERENCE SIGNS LIST

-   -   1, 1A . . . wavelength conversion member     -   1 a, 1 b . . . first and second principal surfaces     -   1 c, 1 d . . . surface layer bottom plane     -   2 . . . glass matrix     -   3 . . . phosphor particle     -   4 . . . slurry     -   5A . . . first green sheet     -   5Aa . . . top surface     -   5Ab . . . under surface     -   5B . . . second green sheet     -   5Ba . . . top surface     -   5Bb . . . under surface     -   6 . . . resin film     -   11 . . . wavelength conversion member     -   11 a, 11 b . . . first and second principal surfaces     -   11 c, 11 d . . . surface layer bottom plane     -   A . . . middle portion     -   B . . . surface layer 

The invention claimed is:
 1. A wavelength conversion member having a first principal surface and a second principal surface opposed to each other, the wavelength conversion member comprising: a glass matrix; and phosphor particles disposed in the glass matrix, wherein concentrations of the phosphor particles in the first principal surface and in the second principal surface are higher than concentrations of the phosphor particles in portions 20 μm inward from the first principal surface and 20 μm inward from the second principal surface.
 2. The wavelength conversion member according to claim 1, wherein a concentration of the phosphor particles in a middle portion between the first principal surface and the second principal surface is low and a concentration of the phosphor particles increases toward the first principal surface and toward the second principal surface.
 3. A method for producing the wavelength conversion member according to claim 1, the method comprising the steps of: preparing a slurry containing glass particles to be the glass matrix and the phosphor particles; applying the slurry to substrates, drying the slurry, and allowing the phosphor particles to sediment downward before completion of the drying to obtain first and second green sheets in each of which a concentration of the phosphor particles in an under surface is higher than a concentration of the phosphor particles in a top surface; and stacking the first and second green sheets so as to superpose the top surfaces thereof and bonding and firing the first and second green sheets together.
 4. The method for producing the wavelength conversion member according to claim 3, further comprising the step of polishing the first principal surface and/or the second principal surface of the wavelength conversion member. 